Fin-plate heat exchanger

ABSTRACT

A fin-plate heat exchanger is arranged to allow heat to be exchanged between a first fluid and a second fluid. The fin-plate heat exchanger comprises: a core with first flow paths for the first fluid and second flow paths for the second fluid; a plurality of separating plates; a plurality of fin components; a plurality of first enclosure bars; and a plurality of second enclosure bars. The heat exchanger further comprises a manifold arranged in fluid communication with each of the first flow paths of the core. The manifold and the core are formed as one integral piece, said integral piece comprising a stack of laminate members and said fin components. The plurality of laminate members comprise: first fluid enclosure structures each including a first manifold section.

FOREIGN PRIORITY

This application claims priority to European Patent Application No.18275099.2 filed Jul. 19, 2018, the entire contents of which isincorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a fin-plate heat exchanger and amethod of manufacturing a fin-plate heat exchanger, particularly for usein aerospace applications.

BACKGROUND

A fin-plate heat exchanger is a known type of heat exchanger.

It typically comprises a core that has a plurality of first flow pathsand a plurality of second flow paths. The first flow paths are incommunication with a manifold that communicates a first fluid (such asoil) through the first flow paths. The second flow paths are arranged toallow a second fluid (such as air) to pass. The first and second flowpaths are generally planar and are arranged in a stacked arrangement,where second flow paths are located above and below a given first flowpath, and first flow paths are located above and below a given secondflow path. Separating the flow paths are separating plates that allowheat to transfer between the first and second flow paths.

To assist the transfer of heat, fins are provided in the first andsecond flow paths. The fins extend between adjacent separating plates.The fins are orientated in a direction to assist or guide fluid flow.

Adjacent separating plates are separated by enclosure bars. Theenclosure bars act to enclose respective first and second flow paths.Together with the separating plates, the enclosure bars act to definethe first and second flow paths in the core.

The fin-plate heat exchanger also comprises a manifold that is in fluidcommunication with the first flow paths, but is not in fluidcommunication with the second flow paths. The manifold can supply and/orreceive the first fluid to and/or from the core.

Such a typical fin-plate heat exchanger is conventionally made in thefollowing way.

The core is made by forming a stack of components. This is achieved byfirst providing a base plate. On top of the base plate, enclosure barsfor the first fluid path are placed, and a fin component (such as acorrugated sheet) is placed. On top of these, a separating plate isplaced. On top of this, enclosure bars for the second fluid path areplaced, and a fin component (such as a corrugated sheet) is placed. Ontop of this, a separating plate is placed. This is repeated until thestack of a desired size is formed. To finish the stack, on top of theupper-most enclosure bars and the upper-most fin component, a top plateis placed.

The stack is then brazed together to form the core.

The manifold is made by a separate process, such as by casting,machining or fabrication.

The heat exchanger is then formed by welding the manifold and/orinterface flanges to the core together.

However, the present inventors have identified a desire to provide amore reliable and light-weight heat exchanger that is quicker andcheaper to produce due to the elimination of welding process.

SUMMARY

Viewed from a first aspect, the invention provides a fin-plate heatexchanger for allowing heat to be exchanged between a first fluid and asecond fluid. The fin-plate heat exchanger includes a core comprising: aplurality of first flow paths for the first fluid and a plurality ofsecond flow paths for the second fluid; a plurality of separatingplates, adjacent first and second flow paths being separated byrespective separating plates; a plurality of fin components extendingthrough respective first and second flow paths and extending betweenadjacent separating plates; a plurality of first enclosure barsextending between adjacent separating plates, the first enclosure barsbeing arranged to at least partially define the first flow path; and aplurality of second enclosure bars extending between adjacent separatingplates, the second enclosure bars being arranged to at least partiallydefine the second flow path. The heat exchanger also includes a manifoldarranged in fluid communication with each of the first flow paths of thecore. The manifold and the core are formed as one integral piece, saidintegral piece comprising a stack of laminate members and said fincomponents. The plurality of laminate members comprise: a plurality offirst fluid enclosure structures for enclosing the first flow path, eachfirst fluid enclosure structure comprising a first manifold section andsaid first enclosure bars; a plurality of second fluid enclosurestructures for enclosing the second flow path, each second fluidenclosure structure comprising at least one second enclosure bar, and atleast some of the of the second fluid enclosure structures comprising asecond manifold section; the plurality of separating plates. Eachseparating plate comprises a third manifold section, and each separatingplate separates each first enclosure structure from adjacent secondenclosure structures. The first, second and third manifold sections areshaped to form the manifold when the plurality of laminate members arestacked.

The first manifold section may be on a first laminate member, the secondmanifold section may be on a second laminate member, and the thirdmanifold section may be on a third laminate member, with the first,second and third laminate members being stacked in sequence. Thissequence may be repeated to build up a heat exchanger with multipleparallel flow paths formed via multiple sets of first, second and thirdlaminate members.

The fin-plate heat exchanger may comprise at least one flange formounting the heat exchanger to other components, wherein the manifold,the core and the at least one flange are formed as one integral piece,wherein each of the first enclosure structures, each of the separatingplates and at least some of the second enclosure structures compriserespective flange portions, wherein the flange portions are shaped toform the at least one flange when the plurality of laminate members arestacked.

The integral piece may comprise the laminate members and the fincomponents brazed together.

Optionally, the manifold is not welded to the core.

Optionally the laminate members do not comprise fins.

The manifold may comprise manifold features for allowing the first fluidto be supplied to and/or received from the first flow paths, wherein thefirst, second and third manifold sections each comprise respectivefeatures that form the manifold features when the plurality of laminatemembers are stacked.

The fin-plate heat exchanger may comprise a base plate and a top plate,wherein the laminate members comprise the base plate and the top plate,wherein the base plate forms the lower-most layer of the stack and thetop plate forms the upper-most layer of the stack, wherein the baseplate and the top plate each comprise a fourth manifold portion and acore portion, wherein the base plate and the top plate are each shapedsuch that the core portion encloses the core and the fourth manifoldportion encloses the manifold.

The laminate members may be produced by additive manufacturing and/orsubtractive manufacturing.

The fin components are optionally not made by either additivemanufacturing or subtractive manufacturing.

The invention further extends to a method of manufacturing a fin-plateheat exchanger, wherein the heat exchanger is as discussed above and themethod comprises: stacking the laminate members and the fin components;and joining the laminate members and the fin components together to formthe integral piece.

Optionally the method does not include joining the manifold and the coretogether.

At least some of the laminate members may be produced by additivemanufacturing.

At least some of the laminate members may be produced by subtractivemanufacturing.

In one example at least some of the laminate members are produced bysubtractive manufacturing and the separating plates are produced bysubtractive manufacturing.

The method may comprise removing excess material from the integral pieceafter the joining process.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the disclosure will now be described by way ofexample only and with reference to the accompanying drawings in which:

FIG. 1 shows an exemplary embodiment of the fin-plate heat exchanger;

FIG. 2 shows details of the components of the fin-plate heat exchangerof FIG. 1;

FIGS. 3A and 3B show details of the components of the fin-plate heatexchanger of FIG. 1;

FIG. 4 shows details of the components of the fin-plate heat exchangerof FIG. 1;

FIG. 5 shows another view of the of the fin-plate heat exchanger of FIG.1;

FIG. 6 shows an exemplary embodiment of a method of manufacturing afin-plate heat exchanger; and

FIG. 7 shows an example of a flow path in an exemplary embodiment of thefin-plate heat exchanger.

DETAILED DESCRIPTION

As mentioned above, in a first aspect, disclosed is a fin-plate heatexchanger for allowing heat to be exchanged between a first fluid and asecond fluid. The fin-plate heat exchanger comprises a core comprising:a plurality of first flow paths for the first fluid and a plurality ofsecond flow paths for the second fluid; a plurality of separatingplates, adjacent first and second flow paths being separated byrespective separating plates; a plurality of fin components extendingthrough respective first and second flow paths and extending betweenadjacent separating plates; a plurality of first enclosure barsextending between adjacent separating plates, the first enclosure barsbeing arranged to at least partially define the first flow path; and aplurality of second enclosure bars extending between adjacent separatingplates, the second enclosure bars being arranged to at least partiallydefine the second flow path. The fin-plate heat exchanger also comprisesa manifold arranged in fluid communication with each of the first flowpaths of the core. The fin-plate heat exchanger is characterised in thatthe manifold and the core are formed as one integral piece, saidintegral piece comprising a stack of laminate members and said fincomponents. The plurality of laminate members comprise: a plurality offirst fluid enclosure structures for enclosing the first flow path, eachfirst fluid enclosure structure comprising a first manifold section andsaid first enclosure bars; a plurality of second fluid enclosurestructures for enclosing the second flow path, each second fluidenclosure structure comprising a second enclosure bar, and at least someof the of the second fluid enclosure structures comprising a secondmanifold section; the plurality of separating plates, each separatingplate comprising a third manifold section, and each separating plateseparating each first enclosure structure from adjacent second enclosurestructures. The first, second and third manifold sections are shaped toform the manifold when the plurality of laminate members are stacked.Thus, first manifold section may be on a first laminate member, thesecond manifold section may be on a second laminate member, and thethird manifold section may be on a third laminate member, with thefirst, second and third laminate members being stacked in sequence. Thissequence may be repeated to build up a heat exchanger with multipleparallel flow paths formed via multiple sets of first, second and thirdlaminate members. This fin-plate heat exchanger should be more reliablethan conventional fin-plate heat exchangers due to the elimination ofwelding process. In conventional fin-plate heat exchangers, the manifoldand core are formed separately, and are then joined together, forexample by a welding process. However, the inventors have identifiedthat such welding joints are susceptible to thermo-mechanical fatiguecracking. The present heat exchanger does require any such weld, andtherefore does suffer such reliability issues.

Further, the present fin-plate heat exchanger may be lighter in weightthan conventional fin-plate heat exchangers, which is of particularrelevance in industries such as aerospace. Due to the presence of theweld (which is a potential weakness, as mentioned above) conventionalfin-plate heat exchangers may be built heavier than the present heatexchanger.

Further still, the present fin-plate heat exchanger may be built morerapidly and cheaply than conventional fin-plate heat exchangers. Sinceboth the manifold and the core are made as one integral piece from thelaminate members, there is no need to manufacture the manifold and thecore separately and then join them together, which reduces constructiontime. Further, the laminate members can be manufactured very quickly(for example from additive or subtractive manufacturing processes) andthe fin components can be provided as standard components. Thus, all ofthe components that make up the heat exchanger can be made or providedvery quickly. In addition, the form of the laminate members can bevaried quickly, which allows great flexibility and quick changing of theoverall heat exchanger design, especially in comparison to when aconventional manifold is made from a cast in a mould or machined fromsolid or fabricated joining individual components.

As mentioned above, the present heat exchanger is a fin-plate heatexchanger. This is a specific type of heat exchanger and is different toother types of heat exchanger, such as microchannel heat exchangers orheat exchangers where pins (or other heat conducting elements) are usedin the flow paths.

The heat exchanger may be arranged to exchange heat only between thefirst and second fluids, i.e. there may be no additional fluids present.

As can be understood from the description of the core above, the core ofthe present heat exchanger may be similar to or identical to the coresof conventional heat exchangers. The inventors have not intended toalter the design of the core. Indeed, one of the purposes of the presentinvention is to produce a fin-plate heat exchanger that has the same (ora similar) form to conventional fin-plate heat exchangers, but also hasthe advantages listed above. The inventors have achieved this by theinnovative design of the laminate members discussed herein.

Thus, the core may comprise a plurality of first flow paths arranged ina layered fashion. Between said first flow paths may be second flowpaths. The first and second flow paths may be separated by separatingplates. The first and second flow paths may be generally planar and thefirst and second fluids may move in parallel to said planes.

The core may comprise a first end and a second end, the first end beingthe end to which the manifold is attached and the second end beingopposite said first end. The core may comprise a bottom and a top. Thetop and the bottom being the extremes of the core in the directiongenerally normal to the direction of the stack (i.e. generally parallelto the normal of the plane defined by the separating plates, see below).The core may comprise a first side and a second side, the first andsecond sides extending between the top and bottom and the first andsecond ends, and being opposite each other. The core may be shaped in ageneral cuboid-shape.

Adjacent first and second flow paths may be in thermal communicationwith each other (e.g. via the fins and the separating plates). Forexample, one first flow path may be in communication with two secondflow paths (the second flow paths above and below the first flow path);and one second flow path may be in communication with two first flowpaths (the first flow paths above and below the first flow path).

The separating plates may be generally planar (herein “planar” may meantotally flat, or may be a curved plane). The first and second flow pathsmay be correspondingly planar. The separating plates (and hence the flowpaths) may be stacked in a way such that they are separated from eachother in a direction generally normal to said plane. The separatingplates may have a rectangular area.

Each fin component may be an integral piece comprising multiple fins(such as a corrugated sheet). There may be only one integral piece perflow path. However, there may be more than one. Alternatively, each fincomponent can comprise only one fin, and a plurality of such componentsare provided separately within each flow path.

The fin components may be placed between adjacent separating plates andhence in said flow paths. The fins may guide the fluid in said flowpaths.

As is known, fins are generally planar heat transfer elements thatextend between adjacent separating plates and extend generally in thedirection of fluid flow. They are different from pins and other heattransfer elements.

The first enclosure bars may be located at the first and second sides ofthe core. The first enclosure bars may be located between separatingplates at the periphery of the separating plates. There may be one firstenclosure bar between two adjacent separating plates at the first sideand another first enclosure between the same two adjacent separatingplates at the second side. There may not be any second enclosure barspresent between said separating plates. There may be second enclosurebars present on the other side of both said separating plates. The firstenclosure bars and the separating plates define a first flow path whereat least one end of the core is open.

The second enclosure bars may be located at the first and second ends ofthe core. The second enclosure bars may be located between separatingplates at the periphery of the separating plates. There may be onesecond enclosure bar between two adjacent separating plates at the firstend and another second enclosure between the same two adjacentseparating plates at the second end. There may not be any firstenclosure bars present between said separating plates. There may befirst enclosure bars present on the other side of both said separatingplates. The second enclosure bars and the separating plates define afirst flow path where at least one side of the core is open.

Stated differently, a given separating plate will be separated from anadjacent separating plate above/below by first enclosure bars and by anadjacent separating plate below/above by second enclosure bars.

The manifold is for supplying the first fluid to and/or receiving thefirst fluid from the first fluid paths. It is not in communication withthe second fluid paths.

The manifold may be located at the first end of core.

There may be only one manifold. In this case, the second end of the coreof the first flow paths may be enclosed by another first enclosure bar.The manifold may comprise a supply and a return path for the firstfluid. There may be a guiding structure present in the core to guide thefluid through the first flow paths from the supply to the return path.

There may be two manifolds. In this case, the manifolds may be presentat either end of the core.

As mentioned above, in the present fin-plate heat exchanger, themanifold and the core are formed as one integral piece. This means thatthey are not two separate pieces that have been joined together, forexample by welding. Rather, they are formed in the same formationprocess (such as the brazing process mentioned below).

There may also be flanges formed in the same integral piece, with theflanges acting as interface flanges. These interface flanges may beformed by interface flange sections provided on some or all of thelaminate members.

The stack of laminate members are laminated together. Lamination isknown term in the art and is not discussed herein. The stack may bereferred to as a laminated stack.

Each laminate member may be an integral piece, i.e. they are formed inone process and do not comprise any joints, such as welds.

The stack may be arranged by having separating plates separated byalternating first and second enclosure structures.

The first manifold sections of respective first enclosure structures maybe the same as or different to each other. The second manifold sectionsof respective second enclosure structures may be the same as ordifferent to each other (and the same as or different to the firstmanifold sections). The third manifold sections of respective separatingplates may be the same as or different to each other (and the same as ordifferent to the first and second manifold sections). The form of therespective first, second and third manifold sections can be such that,when the laminate members are stacked appropriately, a manifold with thecorrect form/features results. The first, second and third manifoldsections are effectively cross-section slices of the overall manifold,such that when they are placed together the manifold is formed. Thus,first manifold section may be on a first laminate member, the secondmanifold section may be on a second laminate member, and third manifoldsection may be on a third laminate member, with the first, second andthird laminate member being stacked in sequence. This sequence may berepeated to build up a heat exchanger with multiple parallel flow pathsformed via multiple sets of first, second and third laminate members.

Having the laminate members comprise such manifold sections isadvantageous, not only because the manifold and the core can be formedas an integral piece, but also because it means the features of themanifold (e.g. the pipes/openings/etc.) do not need to be machined intothe manifold after the stack is laminated. Further it allows the form ofthe manifold to be varied easily from one heat exchanger to the next.

The fin-plate heat exchanger may comprise at least one flange formounting the heat exchanger to other components. Such other componentsmay be nearby supporting structures, such as an airframe, or othercomponents such as ducts and pipes.

The manifold, the core and the at least one flange may be formed as oneintegral piece. This may be achieved by having each of the firstenclosure structures, each of the separating plates and at least some ofthe second enclosure structures (and preferably each of the secondenclosure structures) comprise respective flange portions, wherein theflange portions are shaped to form the at least one flange when theplurality of laminate members are stacked.

Conventionally, such flanges are welded onto the core/manifold after thecore is formed. However, by providing flange portions in the laminatedmembers, the flanges can be formed at the same time as the core and canbe integral with the core. This can improve reliability, reduceconstruction time and reduce weight. Thus, the flange may not be joined(e.g. welded) to the remainder of the heat exchanger.

There may be a plurality of flanges each formed by a respectiveplurality of flange portions in the laminate members. There may be(exactly) four flanges, one located proximate each corner of the core.

The integral piece may comprise (or consist of) the laminate members andthe fin components adhered (e.g. brazed) together. There may of coursebe some adhering (e.g. brazing or bonding) material present too.

As mentioned above, the manifold may not be joined (e.g. welded) to thecore. Said flange(s) may not be joined (e.g. welded) to the remainder ofthe heat exchanger. There may be no flange or manifold joined (e.g.welded) to the remainder of the heat exchanger. There may be no weldpresent in the heat exchanger.

The laminate members may not comprise any fins (or any other secondaryassisting heat transfer surfaces, such as pins). Rather, the fins mayonly be provided in the fin components, which may not be laminatedmembers. The fins may be provided in a conventional way, such as by acorrugated sheet. The fins may be placed in the stack (betweenseparating plates) and adhered (e.g. brazed) together with the laminatedmembers.

As mentioned above, the manifold may comprise manifold features forallowing the first fluid to be supplied to and/or received from thefirst flow paths. The first, second and third manifold sections may eachcomprise respective features that form the manifold features when theplurality of laminate members are stacked.

The manifold features may comprise fluid paths, pipes, openings, etc.for the first fluid.

If only one manifold is present in the heat exchanger, the manifoldfeatures may comprise a supply fluid path and a return fluid path, eachbeing open to the first fluid paths.

If two manifolds are present (e.g. one at each end of the core), then afirst manifold may comprise a supply fluid path and a second manifoldmay comprise a return fluid path, the supply and the return paths beingopen to the first fluid paths.

The fin-plate heat exchanger may comprise a base plate and a top plate.These may also be referred to as “side plates” in the art. The baseplate may be located at the bottom of the stack and the top plate may belocated at the top of stack.

The laminate members may comprise the base plate and the top plate. Thebase plate and the top plate may each comprise a fourth manifold portionand a core portion. The base plate and the top plate may be each shapedsuch that the core portion encloses the core and the manifold portionencloses the manifold.

The top and the base plates may effectively provide some externalstructure to the heat exchanger and may seal the manifold and/or thecore.

The laminate members may consist of the first enclosure structures, thesecond enclosure structure, the separating plates, the base plate andthe top plate. Thus, the integral member may be formed solely of thefirst enclosure structures, the second enclosure structure, theseparating plates, the base plate, the top plate and the fin components(and some adhering material, such as brazing material).

The laminate members may be produced by additive manufacturing (such aslaser powder bed fusion or energy metal deposition) and/or subtractivemanufacturing (such as etching, laser cutting, water jet cutting, wireeroding or high-speed machining). Different laminated members can bemade by the same or different methods. The top plate, the base plate,the first enclosure structures or the second enclosure structures may bemade by either additive manufacturing or subtractive manufacturing.However, the separating plates are preferably made by subtractivemanufacturing.

The present heat exchanger allows a large proportion of its constituentcomponents to be made by these methods. Conventional methods do notallow this. This is advantageous since it allows a great deal offlexibility in design of heat exchanger, and the heat exchanger's formcan be varied very quickly. Further, it can increase the speed of themanufacture.

The fin components may be manufactured by a different technique to thelaminate members. Thus, they may be made during a separate process. Insome examples fin components are not made by additive manufacturing orby subtractive manufacturing. Rather, the fins may be made (or supplied)in a conventional way for heat exchanger finstock (for example bypressing/bending a sheet to form a corrugated and/or perforated sheet).

The present heat exchanger allows the use of conventional fin componentsas one of its constituent components. This is advantageous since itallows the structure of the heat exchanger to be made quickly andstrongly (as mentioned above), but can still use the conventional fincomponents, which are cheap and easy to make/supply.

As can be appreciated, the inventors have devised a sort of “hybrid”technology, that is somewhere between producing a fin-plate heatexchanger purely from a rapid manufacture process (such as additivemanufacturing), producing a fin-plate heat exchanger by a pure laminatedprocess (such as in EP 2474803, discussed below) and by producing afin-plate heat exchanger by conventional means (as discussed in thebackground section).

The present method is advantageous over these alternatives since it isquicker and more reliable than conventional means, but is morestraightforward than using pure rapid manufacture (which may struggle toproduce such a complex fin-plate heat exchanger) or by using a purelaminated process (where the fins would be required to be part of eachlaminate member making up a given layer). Thus, the inventors have foundan improved way of manufacturing a fin-plate heat exchanger.

For instance, it may be known (for example from US 2015/260459 or EP2474803) to manufacture a core and a manifold as one integral piece fromlaminate members.

However, in the prior art there is no teaching or suggestion of usingfin components in both the first and second flow paths in such alaminated core structure. Rather, in the prior art, whenever a laminatedintegral core and manifold are produced, the heat transfer elements usedare pins or the like.

Further, these prior art heat exchangers are made from a pure laminatedprocess, where the heat transfer elements (the pins) are integral partsof each laminated member. Pins are used as the heat transfer elementsbecause they lend themselves to being formed in this laminated way.However, it is much more difficult to produce fins in a laminated way(which is why it has not been done in the prior art).

In contrast to these prior art examples, in the present heat exchangerthe fins are provided as separate to the laminate members (e.g. the finsare provided as conventional fin components (e.g. corrugated sheets)whereas the laminate members are provided as rapidly-produced (e.g.subtractive or additive manufactured) components). Thus, the presentinventors have developed a “hybrid” type technology that is that issomewhere between producing a fin-plate heat exchanger purely from arapid manufacture process, producing a fin-plate heat exchanger by apure laminated process, and producing a fin-plate heat exchanger byconventional means.

The fin-plate heat exchanger may be for use in an aircraft. Forinstance, it may be for use in an aircraft engine, or possibly in an airmanagement system in an aircraft.

The fin-plate heat exchanger may be for use with a first fluid that canvary between −40° C. to 210° C. The fin-plate heat exchanger may be foruse with a second fluid that can very between −50° C. to 100° C. Thefin-plate heat exchanger may be for use with a first fluid that can varybetween 3 kPa to 150 kPa. The fin-plate heat exchanger may be able tofunction over both of these ranges, and possibly beyond. The fin-plateheat exchanger may comprise the first and second fluids.

The first fluid may be a liquid, such as oil and the second fluid may bea gas, such as air or any combinations thereof.

In a second aspect, provided is a method of manufacturing a fin-plateheat exchanger. The heat exchanger may be the heat exchanger of thefirst aspect. The method may comprise stacking the laminate members andthe fin components; and adhering (e.g. brazing) the laminate members andthe fin components together to form the integral piece.

The stacking may be as set out above, i.e. a first enclosure structure,then a separating plate, then a second enclosure structure, then aseparating plate, then a first enclosure, etc.

Stacking the laminate members may comprise placing a first (or second)enclosure structure on top of the base plate; placing a separating plateon top of the first (or second) enclosure structure; placing a second(or first) enclosure structure on top of the separating plate; placing aseparating plate on top of the second (or first) enclosure structure;and then repeating the first enclosure structure, separating plate,second enclosure structure pattern until the core is complete. Then thetop plate is placed on the upper most enclosure structure (which may bea first or a second enclosure structure).

In addition to these components, adhering (e.g. brazing) material mayalso be added during the stacking. For instance, adhering material maybe added between the base plate and the lower most enclosure structure.Adhering material may be added between the top plate and the upper mostenclosure structure.

Adhering material may be added between each layer of the stack. However,preferably it is only added in the positions mentioned in the paragraphabove.

To bond the remainder of the structure, adhering material may beprovided on both sides of the separating plates (i.e. the separatingplates may be formed from a sheet of material that already has adheringmaterial cladded onto both of its upper and lower surfaces).

The method may not include joining (e.g. welding) the manifold and thecore together. As mentioned above, conventionally the manifold and thecore of a fin-plate heat exchanger are manufactured separately, and thenwelded together. The inventors have devised a method where this step maynot be necessary.

The method may comprise producing at least some of the laminate membersby additive manufacturing. The first enclosure structures may beproduced by additive manufacturing. The second enclosure structures maybe produced by additive manufacturing. The top and base plates may beproduced by additive manufacturing.

Additionally/alternatively, the method may comprise producing at leastsome of the laminate members by subtractive manufacturing. The firstenclosure structures may be produced by subtractive manufacturing. Thesecond enclosure structures may be produced by subtractivemanufacturing. The top and base plates may be produced by subtractivemanufacturing.

The method may comprise producing the separating plates by subtractivemanufacturing. This is preferable (instead of additive manufacturing),since the separating plates may be made from sheets where adheringmaterial is already present. Such a material would be difficult toproduce by additive manufacture.

The method may comprise removing excess material from the integral pieceafter the adhering process. There may be excess material present nearthe manifold and in other places, so as to provide enough structuralintegrity in the stack during adhering (where the stack may be heldunder pressure). Further, there may be excess material in the flange(s),which may be too big for their intended purpose. Further, holes can bedrilled into the flange(s) so that they can be attached (e.g. bolted) toother components.

The method may not comprise machining the manifold or the core after theintegral piece is formed. There is no need to do so.

The method may comprise producing a first laminated heat exchanger usingany of the methods above, and then producing a second laminated heatexchanger using any of the methods above. The first and the secondlaminated heat exchanger may differ in form, e.g. they be of differentsizes, have different dimensions, have different manifold features, havedifferent areas and thicknesses of flow paths, etc.

Due to the flexibility of the present method, the time taken to producetwo such different heat exchangers may be dramatically reduced incomparison to conventional methods.

Turning now to FIG. 1, shown is a fin-plate heat exchanger 1 inaccordance with an embodiment of the present fin-plate heat exchanger.

The heat exchanger 1 comprises a core 100. The core 100 comprises aplurality of first flow paths 200 for a first fluid and a plurality ofsecond flow paths 300 for the second fluid. The first 200 and second 300flow paths are arranged in an alternating stack and are separated by aplurality of separating plates 101. A plurality of fin components 103extend through respective first 200 and second 300 flow paths and extendbetween adjacent separating plates 101. In FIG. 1, only the fincomponents 103 in the second flow path 300 are shown, since the fincomponents 103 in the first flow path 200 cannot be seen.

First enclosure structures 201 act in cooperation with the separatingplates 101 to define the first flow paths 200.

Second enclosure structures 301 act in cooperation with the separatingplates 101 to define the second flow paths 300.

The core 100 comprises a first end 151 and a second end 152; a bottom153 and a top 154; and a first side 155 and a second side 156.

The fin-plate heat exchanger 1 also comprises a manifold 400 arranged influid communication with each of the first flow paths 200 of the core100.

The manifold 400 comprises manifold features, such as supply line 401and a return line 402 for supplying the first fluid to the first fluidpaths 200 and receiving fluid from the first fluid paths 200respectively.

The fin-plate heat exchanger 1 comprises flanges 600. The flanges 600are for attaching the heat exchanger 1 to other adjacent components.

The manifold 400, the flanges 600 and the core 100 are formed as oneintegral piece.

The integral piece comprises a stack of laminate members 101, 501, 502,201, 301 and said fin components 103.

The plurality of laminate members 101, 501, 502, 201, 301 comprise: thefirst fluid enclosure structures 201; the second fluid enclosurestructures 301; the plurality of separating plates 101; a base plate 501and a top plate 502 (not shown in FIG. 1).

The stack is formed by placing a first enclosure structure 201 and atleast one fin component (not shown) on top of the base plate 501. On topof the first enclosure 201 and the at least one fin component, aseparating plate 101 is placed. On top of the separating plate 101, asecond enclosure structure 301 and a fin component 103 is placed. On topof these, another separating plate 101 is placed. This pattern is thenrepeated until the top 154 of the heat exchanger is reached, when a topplate 502 is placed on top of the uppermost enclosure structure(s) andfin component(s).

As mentioned above, the stack may be brazed together to form theintegral piece.

Regarding FIG. 2, an exemplary first enclosure structure 201 is shown inmore detail.

The first enclosure structure 201 comprises a manifold section 202.

The manifold section comprises manifold feature cut outs 208, 209. Themanifold section 202 is shaped such that, when the first enclosurestructure 201 is placed in the stack, the manifold 400 with the correctfeatures 401, 402 is formed.

The first enclosure structure 201 also comprises a first enclosure bar203 arranged to close off the first side 155 of the first fluid path 200when placed between two separating plates 101.

The first enclosure structure 201 also comprises a second enclosure bar204 arranged to close off the second side 156 of the first fluid path200 when placed between two separating plates 101.

The first enclosure structure 201 may also comprise a third enclosurebar 206 arranged to close off the second end 152 of the first fluid path200 when placed between two separating plates 101.

The first enclosure structure 201 may also comprise a guiding structure207 arranged to guide the flow of the first fluid through the first flowpath 200 from the supply 401 to the return 402 of the manifold.

The first enclosure structures 201 leave the first end 151 of the firstflow path 200 open.

Other guides may be present, or no guides may be present. For instance,it may be that there are two manifolds present, one at either end 151,153.

The first enclosure structure 201 also comprises a plurality of flangeportions 210 arranged such that, when the first enclosure structure 201is placed in the stack, the flanges 600 are formed.

Each first enclosure structure 201 may be the same as one another, ormay be different. The precise form of each first enclosure structurewill depend on the desired shape and features of the heat exchanger 1.

Regarding FIGS. 3a and 3b , shown are exemplary second enclosurestructures 301. The enclosure structures of FIGS. 3a and 3b work incombination with each other to close respective ends 151, 152 of thecore 100 between two separating plates 101 so as to define a givensecond flow path. In the example shown here, the second enclosurestructure 301 shown in FIG. 3a closes the second end 152 and the secondenclosure structure 301 shown in FIG. 3b closes the first end 151 of thesame second flow path 300.

Regarding FIG. 3a , the first enclosure structure 301 comprises a secondenclosure bar 306 arranged to close off the second end 152 of the secondfluid path 300 when placed between two separating plates 101.

Regarding FIG. 3b , the second enclosure structure 301 comprises amanifold section 302. The manifold section comprises manifold featurecut outs 308, 309. The manifold section 302 is shaped such that, whenthe first enclosure structure 301 is placed in the stack, the manifold400 with the correct features 401, 402 is formed.

The second enclosure structure 302 also comprises a first enclosure bar305 arranged to close off the first end 151 of the second fluid path 300when placed between two separating plates 101.

The second enclosure structures 301 leave the first and second sides155, 156 of the second flow path 300 open.

The second enclosure structures 301 also comprise a plurality of flangeportions 310 arranged such that, when the second enclosure structures301 are placed in the stack, the flanges 600 are formed.

Each second enclosure structure 301 of FIG. 3a may be the same as oneanother, or may be different to each other. Each first enclosurestructure 301 of FIG. 3b may be the same as one another, or may bedifferent. The precise form of each first enclosure structure willdepend on the desired shape and features of the heat exchanger 1.

Regarding FIG. 4, an exemplary separating plate 101 is shown in moredetail.

The separating plate 101 comprises a manifold section 102. The manifoldsection comprises manifold feature cut outs 108, 109. The manifoldsection 102 is shaped such that, when the separating plate 101 is placedin the stack, the manifold 400 with the correct features 401, 402 isformed.

The separating plate 101 has a core portion 104 that is solid (unbroken)and extends from the first end 151 to the second end 152 and from thefirst side 155 to the second side 156.

The separating plate 101 also comprises a plurality of flange portions110 arranged such that, when the separating plate 101 is placed in thestack, the flanges 600 are formed.

Each separating plate 101 may be the same as one another, or may bedifferent. The precise form of each separating plate 101 will depend onthe desired shape and features of the heat exchanger 1.

The top and base plates 501, 502 are not shown in detail, but may besimilar to the separating plate 101, but without the manifold features108, 109 (i.e. the top and base plates 501, 502 may be solid (unbroken)so as to close the manifold 400 and the core 100).

FIG. 5 shows a completed fin-plate heat exchanger 1. This is largelyidentical to the fin-plate heat exchanger 1 shown in FIG. 1, except thetop plate 502 is also shown. Further, excess material (such as thehoney-comb material in the manifold sections 102, 202, 402) have beenremoved, and holes have been drilled in the flange.

The fin-plate heat exchanger 1 of the above embodiment comprises onlyone manifold 400. However, it may be possible for two manifolds 400 tobe present, one at each end 151, 152 of the core. In this case, onemanifold may be for supply and one may be for return of the first fluid.To achieve this, additional manifold sections will be needed in thelaminated members, and the manifold features of each will differ fromwhat is shown in the Figures. For instance, third enclosure bar 206 mayneed to be replaced with a manifold section; a manifold section may beneeded to be added to the enclosure bar 306; and a manifold section mayneed to be added at the second end 152 of the separating plate 101. Inthis case, there may be no need for guide 207.

Regarding FIG. 7, it shows in more detail an exemplary first flow path200 defined by an exemplary first enclosure structure 201. The firstflow path comprises three fin components 103 a, 106 b, 103 c.

The first fin component 103 a extends from the manifold section 202 in adirection from the first end 151 toward the second end 152. The fins ofthe first fin component 103 a are orientated in this direction, thusguiding fluid away from the supply line 401 of the manifold 400 betweenthe second enclosure bar 204 and the guiding structure 207.

The second fin component 103 b extends from the manifold section 202 ina direction from the first end 151 toward the second end 152. The finsof the second fin component 103 b are orientated in this direction, thusguiding fluid toward the return line 402 of the manifold 400 between thefirst enclosure bar 203 and the guiding structure 207. The guidingstructure fluidly separates the first and second fin structures 103 a,103 b.

The third fin component 103 c extends between the first and second fincomponents 103 a, 103 b in a direction generally perpendicular to thedirection of the first and second fin components 103 a, 103 b (i.e. thefins of the third fin component 103 c are generally parallel to andproximate to the second end 152 of the heat exchanger). The third fincomponent 103 c guides the fluid from the first fin component 103 a tothe second fin component 103 b between the third enclosure bar 206 andthe guiding structure 207.

Each of the first flow paths may comprise similar or identical fincomponents 103 a, 103 b, 103 c.

The fin component 103 of the second flow paths may be a singlecomponent. It may simply extend, and guide the second fluid, from thefirst side 155 to the second side 156 between the first and secondenclosure bars 305, 306 of the second enclosure structure 301.

Regarding FIG. 6, a method of manufacturing the fin-plate heat exchangeris schematically shown.

In a first step 901, the laminate members 101, 201, 301, 501, 502 areproduced. This may occur by additive or subtractive manufacturing.

In a second step 902, the fin components 103 are formed. This may beachieved by cutting a corrugated sheet to size, and/or by punching aflat sheet such that corrugated fins are produced.

In a third step 903, the laminate members 101, 201, 301, 501, 502 andthe fin components 103 are stacked. Possibly some brazing material isalso placed in appropriate places in the stack.

In a fourth step 904, the stack is brazed to from the integral piece.

In a fifth step 905, excess material is cut off the integral piece.

In a sixth step 906, ancillary components such as relief valves arefitted.

This process can be repeated for a similarly-shaped or adifferently-shaped fin-plate heat exchanger.

1. A fin-plate heat exchanger for allowing heat to be exchanged betweena first fluid and a second fluid, the fin-plate heat exchangercomprising: a core comprising: a plurality of first flow paths for thefirst fluid and a plurality of second flow paths for the second fluid; aplurality of separating plates, adjacent first and second flow pathsbeing separated by respective separating plates; a plurality of fincomponents extending through respective first and second flow paths andextending between adjacent separating plates; a plurality of firstenclosure bars extending between adjacent separating plates, the firstenclosure bars being arranged to at least partially define the firstflow path; and a plurality of second enclosure bars extending betweenadjacent separating plates, the second enclosure bars being arranged toat least partially define the second flow path; and a manifold arrangedin fluid communication with each of the first flow paths of the core;wherein: the manifold and the core are formed as one integral piece;said integral piece comprising a stack of laminate members and said fincomponents; and the plurality of laminate members comprise: a pluralityof first fluid enclosure structures for enclosing the first flow path,each first fluid enclosure structure comprising a first manifold sectionand said first enclosure bars; a plurality of second fluid enclosurestructures for enclosing the second flow path, each second fluidenclosure structure comprising at least one second enclosure bar, and atleast some of the of the second fluid enclosure structures comprising asecond manifold section; and the plurality of separating plates, eachseparating plate comprising a third manifold section, and eachseparating plate separating each first enclosure structure from adjacentsecond enclosure structures, wherein the first, second and thirdmanifold sections are shaped to form the manifold when the plurality oflaminate members are stacked.
 2. The fin-plate heat exchanger as claimedin claim 1, further comprising: at least one flange for mounting theheat exchanger to other components; wherein the manifold, the core andthe at least one flange are formed as one integral piece; wherein eachof the first enclosure structures, each of the separating plates and atleast some of the second enclosure structures comprise respective flangeportions; and wherein the flange portions are shaped to form the atleast one flange when the plurality of laminate members are stacked. 3.The fin-plate heat exchanger as claimed in claim 1, wherein the integralpiece comprises the laminate members and the fin components brazedtogether.
 4. The fin-plate heat exchanger as claimed in claim 1, whereinthe manifold is not welded to the core.
 5. The fin-plate heat exchangeras claimed in claim 1, wherein the laminate members do not comprisefins.
 6. The fin-plate heat exchanger as claimed in claim 1, wherein themanifold comprises manifold features for allowing the first fluid to besupplied to and/or received from the first flow paths; and wherein thefirst, second and third manifold sections each comprise respectivefeatures that form the manifold features when the plurality of laminatemembers are stacked.
 7. The fin-plate heat exchanger as claimed in claim1, further comprising: a base plate; and a top plate; wherein thelaminate members comprise the base plate and the top plate, wherein thebase plate forms the lower-most layer of the stack and the top plateforms the upper-most layer of the stack, wherein the base plate and thetop plate each comprise a fourth manifold portion and a core portion,wherein the base plate and the top plate are each shaped such that thecore portion encloses the core and the fourth manifold portion enclosesthe manifold.
 8. A fin-plate heat exchanger as claimed in any precedingclaim, wherein the laminate members are produced by additivemanufacturing and/or subtractive manufacturing.
 9. The fin-plate heatexchanger as claimed in claim 1, wherein the fin components are not madeby additive manufacturing or subtractive manufacturing.
 10. A method ofmanufacturing a fin-plate heat exchanger as claimed in claim 1, themethod comprising: stacking the laminate members and the fin components(103); and joining the laminate members and the fin components togetherto form the integral piece.
 11. The method as claimed in claim 10,wherein the method does not include joining the manifold and the coretogether.
 12. The method as claimed in claim 10, comprising producing atleast some of the laminate members by additive manufacturing.
 13. Themethod as claimed in claim 10, comprising producing at least some of thelaminate members by subtractive manufacturing.
 14. A method as claimedin claim 13, comprising producing the separating plates by subtractivemanufacturing.
 15. The method as claimed in claim 10, comprisingremoving excess material from the integral piece after the joiningprocess.